Method and apparatus for achieving maximum yield in the electrolytic preparation of group IV and V hydrides

ABSTRACT

A method for generating a hydride gas of metal M 1  in an electrochemical cell comprising a cathode comprising metal M 1 , a sacrificial anode comprising metal M 2 , an initial concentration of aqueous electrolyte solution comprising a metal hydroxide, M 3 OH, wherein the sacrificial metal anode electrochemically oxidizes in the presence of the aqueous electrolyte solution comprising M 3 OH to form a metal salt, and the hydride gas of metal M 1  is formed by reducing the metal M 1  of the cathode. The method comprises the steps of determining solubility profile curves of the metal salt as the M 3 OH is consumed and the metal oxide is formed by the oxidation reaction at various concentrations of M 3 OH; determining a maximum concentration of M 3 OH that, as it is consumed, does not yield a concentration of metal salt that precipitates out of the electrolyte solution; and choosing a concentration of M 3 OH that is in the range of at and within 5% less than the maximum concentration of M 3 OH to be the initial concentration of M 3 OH.

CROSS-REFERENCE TO RELATED APPLICATIONS

This invention claims the benefit of U.S. Provisional Application60/791,840, filed Apr. 13, 2006 titled, “Method and Apparatus forAchieving Maximum Yield in the Electrolytic Preparation of Group IV andV Hydrides”. The disclosure of this provisional application is herebyincorporated by reference.

BACKGROUND OF THE INVENTION

This invention is in the field of electrochemical processes andapparatus. More specifically, the present invention is directed to theelectrochemical synthesis and production of Group IV and V volatilehydrides, and a reactor for carrying out the synthesis. The synthesisand the reactor are designed to more efficiently produce high purityhydrides.

High purity gases are required for semiconductor fabrication and doping.Often these gases are dangerously toxic. Commercial compressed gascylinders store gas at several thousand pounds per square inch pressureand contain one to ten pounds of gas. Hence, centralized production,transportation and storage of these materials presents a hazard to thoseworking with them.

To avoid these hazards, an apparatus has been developed to provide thesedangerous gases to be generated only when they are needed such as, forexample, at a chemical vapor deposition reactor in a semiconductormanufacturing plant. For example, W. M. Ayers, in U.S. Pat. Nos.5,158,656 and 6,080,297, describes an electrochemical apparatus andmethod for supplying volatile hydrides at the proper pressure forintroduction into a chemical vapor deposition reactor. Such processesgenerate metal hydride gas and hydrogen gas from the corresponding metalcathode by employing a sacrificial anode (i.e., an electrode thatcorrodes to an oxide) and hydroxide-based electrolytes in an undividedelectrochemical cell. Such processes, however, do not operateefficiently due to the uncontrolled formation of solid precipitates thatare a byproduct of the electrochemical reaction that occurs within theapparatus. The precipitation of these solids has a negative effect onthe overall yield and quality of the electrochemically generated hydridegas.

Porter, in U.S. Pat. No. 4,178,224, discloses an electrochemical methodfor the synthesis of arsine gas that utilizes a dissolved arsenic saltwith an oxygen evolving anode. With this method, however, the arsineconcentration was limited to less than 25%. Another limitation ofPorter's method was the need to balance pressures and liquid levels inthe divided anode and cathode sections of the electrochemical cell. Thisrequires an inert gas supply to the cell.

U.S. Pat. Nos. 5,427,659, and 5,474,659, disclose the electrochemicalgeneration of hydride gases with aqueous electrolytes under conditionsthat avoid oxygen formation. Although these methods also avoid theformation of solid precipitates, the hydride yield is much lower thandesired.

Thus, while efforts have continued to provide effective means forproducing and delivering hydride gases, there is still a need in the artto improve the quality and quantity of delivered hydride gas productstreams.

BRIEF SUMMARY OF THE INVENTION

The present invention satisfies this need by providing a method forgenerating a hydride gas of metal M₁ in an electrochemical cellcomprising a cathode comprising metal M₁; a sacrificial anode comprisingmetal M₂; an initial concentration of aqueous electrolyte solutioncomprising a metal hydroxide, M₃OH, wherein the sacrificial metal anodeelectrochemically oxidizes in the presence of the aqueous electrolytesolution comprising M₃OH to form a metal salt, and the hydride gas ofmetal M₁ is formed by reducing the metal M₁ of the cathode, the methodcomprising the steps of: determining a solubility profile curve of themetal salt as the M₃OH is consumed and the metal oxide is formed by theoxidation reaction at various concentrations of M₃OH; determining amaximum concentration of M₃OH that, as it is consumed, does not yield aconcentration of metal salt that precipitates out of the electrolytesolution; and choosing a concentration of M₃OH that is in the range ofat and within 5% less than the maximum concentration of M₃OH to be aninitial concentration of M₃OH.

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 shows the reactor diagrammatically and in cross-section used forthe present invention (not a part of this invention).

FIG. 2 is a flow chart of a method according to the present invention.

FIG. 3 is a graph illustrating solubility profile curves according to apreferred embodiment of the present invention.

FIG. 4 is a graph illustrating the improved generation of a hydride gasaccording to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides a method for the production of very highpurity gases such as, for example, hydride gases and the feed of gasproduct streams including such gases at constant composition overextended periods of time.

In one aspect, the present invention provides a method for generating ahydride gas of metal M₁ in an electrochemical cell comprising a cathodecomprising metal M₁, a sacrificial anode comprising metal M₂, and aninitial concentration of aqueous electrolyte solution comprising a metalhydroxide M₃OH, wherein the sacrificial metal anode electrochemicallyoxidizes in the presence of the aqueous electrolyte solution comprisingM₃OH to form a metal salt, and the hydride gas of metal M₁ is formed byreducing the metal M₁ of the cathode. The method comprises the steps ofdetermining solubility profile curves of the metal salt as the M₃OH isconsumed and the metal oxide is formed by the oxidation reaction atvarious concentrations of M₃OH; determining a maximum concentration ofM₃OH that, as it is consumed, does not yield a concentration of metalsalt that precipitates out of the electrolyte solution; and choosing aconcentration of M₃OH that is at and within 5% less than the maximumconcentration of M₃OH to be the initial concentration of M₃OH.

FIG. 1 shows an electrochemical reactor used for the present invention(not a part of this invention). The details of the electrochemicalreactor are discussed in US patent: U.S. Pat. No. 5,158,656, and thedetailed discussions are hereby incorporated by reference. Theelectrochemical reactor comprises a pressure vessel 1. Pressure vessel 1is preferably lined with an unreactive material like Teflon™. Inside thereactor is an electrolytic cell having a cathode 2 comprising metal M₁and sacrificial anode 3 comprising metal M₂. The pressure vessel isconnected through port 4 and manifold 5 to the inlet of CVR 6, in whichhydride gases of metal M₁ are used, for example, to manufacture, and fordoping, semiconductors.

Suitable cathode materials, M₁, for use in the invention include, forinstance, those which contain Sb, As, Se (to make hydrogen selenide), P,Ge, Zn, Pb, Cd and alloys thereof such as, for example, lead arsenic.Suitable anode materials, M₂, include, for example, those containingmolybdenum, tungsten, vanadium, cadmium, lead, nickel hydroxide,chromium, antimony, arsenic and alloys thereof and generally hydrogenoxidation anodes. A redox anode material may also be used, for exampleincluding MnO₂/MnO₃, Fe(OH)₂/Fe₃O₄, Ag₂O/Ag₂O₂, or Co(OH)₃/Co(OH)₂. Inaddition, soluble, oxidizible ionic species with an oxidation potentialless than 0.4 volts versus an Hg/HgO reference electrode can be used asanodes in embodiments of the present invention as disclosed herein.

Illustrative aqueous electrolytes comprising M₃OH that can be used inthe present invention are those in which M₃ is selected from the groupconsisting of alkali or alkaline earth metals. Examples of aqueouselectrolytes comprising M₃OH include, e.g., NaOH, KOH, LiOH, CsOH, NH₄OHand combinations thereof. Water, deuterated water (D₂O) and mixturesthereof may be used in the electrolytes.

A product of the electrochemical reaction at the sacrificial anode isthe formation of a metal salt of the metal M₂ from which the anode ismade. Such metal salts may include metal oxide salts, metal halidesalts, metal nitrate salts, metal sulfate salts or mixtures thereof,depending upon the composition of the anode and the electrolyte. Forexample, in one embodiment, arsine (a hydride of arsenic metal) isproduced by employing a cathode comprising arsenic and a sacrificialanode comprising molybdenum in an electrolyte solution comprisingpotassium hydroxide. In this embodiment, the following electrochemicaloxidation reaction occurs:Mo+2KOH+2H₂O→6e ⁻+K₂MoO₄+6H⁺

The formation of arsine occurs according to the followingelectrochemical reduction reaction at the arsenic cathode,2As+6H₂O+6e−→2AsH₃+6OH⁻

Each mole of hydroxide consumed can theoretically produce one mole ofarsine. In an electrochemical cell with limited volume one wouldanticipate, based on stoichiometry alone, that the highest concentrationof a liquid potassium hydroxide aqueous solution should generate thehighest amount of arsine. This however is not the case.

In practice, however, if one chooses an initial concentration ofpotassium hydroxide that, theoretically, should produce the highestamount of arsine based upon stoichiometry, solid crystals of potassiummolybdate are formed as the process proceeds. The formation of solidmetal salts prevents proper current distribution and operation of thecell limiting the purity and the yield. On the other hand, if onechooses a low concentration of potassium hydroxide then solids will notbe formed but the ultimate yield of the cell to produce arsine will belimited. Both high and low concentrations of the potassium hydroxidelimit the production of arsine in this example. By the method of thepresent invention, yield and purity of the generated hydride gas aresurprisingly higher and operating voltages are stable under operatingconditions where a high concentration of hydroxide electrolyte is usedso that the reaction products of the anode oxidation process are solubleand do not form solids that precipitate in the electrolyte.

Referring now to FIG. 2, the method of the present invention comprisesthe steps of 401 determining a solubility profile curve of the metalsalt as the M₃OH is consumed and the metal oxide is formed by theoxidation reaction at various concentrations of M₃OH; 402 determining amaximum concentration of M₃OH that, as it is consumed, does not yield aconcentration of metal salt that precipitates out of the electrolytesolution; and 403 choosing a concentration of M₃OH that is in the rangeof at and within 5% less than the maximum concentration of M₃OH to bethe initial concentration of M₃OH.

Although the following method of the present invention will now bedescribed by employing a cathode comprising arsenic and a sacrificialanode comprising molybdenum in an electrolyte solution comprisingpotassium hydroxide, one of ordinary skill in the art would understandthe broad applicability of the present invention as it may be used withother cathode materials M₁, anode materials M₂, and electrolytesolutions comprising M₃OH such as, for example, those mentioned above.

Step 401, determining a solubility profile curve of the metal salt asthe M₃OH is consumed and the metal oxide is formed by the oxidationreaction at various concentrations of M₃OH, is preferably carried out bypreparing a solubility profile curve for the metal salt comprising themetal, M₂, from the anode. To prepare a solubility profile curve, it ispreferred that a series of solubility studies is conducted to simulatethe compositions of the electrolyte during various stages ofelectrolysis. The solubility studies are preferably guided by thefollowing three fundamental electrochemical reactions that describe theobserved behavior of the electrochemical generation of hydrides.

As an example, the reactions can involve a sacrificial anode, M₂, and anarsenic cathode in a KOH electrolyte:

Anode oxidation reaction:M₂+2 (n−m)OH⁻→M₂O_((n−m)) ^((n−2m)−) +ne ⁻+(n−m) H₂O  Equation 1where m and n are stoichiometric coefficients which depend on the natureof the sacrificial anode metal M₂.Cathode reduction reaction to make arsine (hydride):As+3H₂O+3e ⁻→AsH₃+3OH⁻  Equation 2Cathode reduction reaction to make hydrogen:2H₂O+2e ⁻→H₂+2OH⁻  Equation 3

From these electrochemical mass balance equations one can predict theamount of KOH consumed and the amount of the sacrificial metal salt,M₂O_((n−m)) ^((n−2m)−), that is produced. If the sacrificial metal usedis molybdenum the n=6 and m=2 and M₂O_((n−m)) ^((n−2m)−)=MoO₄ ²⁻. In aKOH solution with a molybdenum anode the salt produced is K₂MoO₄. Eachmole of K₂MoO₄ produced will consume 2 moles of KOH and 2 moles of wateraccording to the above equations. This allows one to simulate thecomposition of the electrolyte as KOH is consumed.

Therefore, to determine the solubility profile curve of the metal saltas the M₃OH is consumed and the metal oxide is formed by the oxidationreaction at various concentrations of M₃OH, a series of aqueoussolutions at 25° C. were prepared using KOH, water and K₂MoO₄ tosimulate compositions of the electrolyte corresponding to theelectrochemical reactions listed above. The KOH, water and K₂MoO₄ werecombined and mixed using a magnetic stir-bar and a magnetic stirrer in asealed polyethylene bottle for 24 hours at 25° C. The liquid phase wasseparated from the solid phase by filtration. The liquid phase wasweighed and the compositions of the liquid and solid phases weredetermined usingInductively-Coupled-Plasma-Atomic-Emission-Spectroscopy, ICP-AES. Thecompositions and results are illustrated in Table 1 and Table 2, for KOHconcentrations of 45% and 38%, respectively.

FIG. 3 graphically depicts the solubility profile curves that representthe data provided by Table 1. Referring to FIG. 3, the percent of themetal salt in solution is plotted as a function of the decreasing amountof KOH when the initial concentration of KOH was 45%. Table 2 confirmsthat, at an initial KOH concentration of 38%, metal salt precipitate wasavoided. Different systems with different electrodes and electrolytescan be examined using the same methodology to identify regions wheresolids will not precipitate.

Step 402, i.e., determining a maximum concentration of M₃OH that, as itis consumed, does not yield a concentration of metal salt thatprecipitates out of the electrolyte solution, is preferably performedafter the solubility profile curve (step 401) is determined because thesolubility profile curve preferably serves as a guide in determining themaximum concentration of M₃OH. Preferably, step 402 is accomplished bydetermining operating lines on the solubility profile curve.

In a preferred method of determining an operating line, anelectrochemical test cell is constructed with a sacrificial anode ofchoice, metal or metal alloy M₂ and the cathode metal or metal alloy M₁.Typically the anode and the cathode are separated by 1 to 10 cm in avertical orientation. The electrolysis cell is sealed and the gasevolved at the cathode is allowed to vent though an opening in the lidof the cell, through a gas mass flow meter, to monitor the quantity ofgas evolved, and into an analytical instrument which can characterizethe gas composition. Typical gas analysis instruments suitable for thisare infrared analyzers, mass spectrometers and time-of-flight analyzers.

TABLE 1 Experimental solubility study to determine the initialcomposition of electrolyte to avoid solids Relationship between KOH andK₂MoO₄: Each mole of K₂MoO₄ produced, consumes 2 moles of KOH and 2moles of H₂O Experimental design simulating the net composition ofelectrolyte during electrolysis: 45% KOH and molybdenum electrode KOH8.1 7.3 6.5 5.7 4.9 4.1 3.2 2.4 1.6 0.8 0.0 (grams dry basis) K₂MoO₄ 0.01.7 3.4 5.2 6.9 8.6 10.3 12.0 13.8 15.5 17.2 (grams) Water 9.9 9.6 9.49.1 8.9 8.6 8.3 8.1 7.8 7.6 7.3 (grams) Total 18.0 18.6 19.3 19.9 20.621.2 21.9 22.5 23.2 23.8 24.5 (grams) net KOH 45.0 39.1 33.6 28.4 23.619.1 14.8 10.8 7.0 3.4 0.0 (wt %) net 0.0 9.2 17.8 25.9 33.4 40.5 47.153.4 59.3 64.9 70.2 K₂MoO₄ (wt %) Solids No Yes Yes Yes Yes Yes Yes YesYes Yes Yes formed on mixing Composition of the liquid and solid phaseafter solids percipitated at 25° C. from compositions simulating astarting point of 45% KOH grams of 18.0 18.6 18.5 18.7 19.0 19.3 19.619.8 20.0 20.0 20.1 liquid *wt % 45.0 39.1 33.6 28.4 23.6 19.1 14.8 10.87.0 3.4 0.0 KOH in solution *wt % 0.0 8.8 14.4 20.9 27.7 34.4 40.8 46.952.7 58.2 63.6 K₂MoO4 in solution grams of 0.00 0.09 0.77 1.25 1.62 1.972.34 2.75 3.24 3.80 4.43 solid wt % None 100 100 100 100 100 100 100 100100 100 K₂MoO4 in solids *The compositions of the liquid and solid phasewere determined using Inductively coupled plasma Atomic EmissionSpectroscopy, ICP-AES.

TABLE 2 Experimental design simulating the net composition ofelectrolyte during electrolysis: 38% KOH and molybdenum electrode KOH8.1 7.3 6.5 5.7 4.9 4.1 3.2 2.4 1.6 0.8 0.0 (grams dry basis) K₂MoO₄ 0.01.7 3.4 5.2 6.9 8.6 10.3 12.0 13.8 15.5 17.2 (grams) Water 13.2 13.012.7 12.4 12.2 11.9 11.7 11.4 11.1 10.9 10.6 (grams) Total 21.3 22.022.6 23.3 23.9 24.6 25.2 25.9 26.5 27.2 27.8 (grams) net KOH 38.0 33.228.7 24.4 20.3 16.5 12.9 9.4 6.1 3.0 0.0 (wt %) net 0.0 7.8 15.2 22.228.8 35.0 40.9 46.5 51.9 57.0 61.8 K₂MoO₄ wt % Solids No No No No No NoNo No No No No formed on mixing

A known quantity and concentration of KOH electrolyte is added to thetest cell. The test cell is electrically connected to a direct current,DC, constant current power supply with the anode and cathode attached tothe positive and negative terminal respectively, of the power supply.Electrolysis is initiated by setting the constant current supply whilethe quantity of gas and the net charge passed through the system aremonitored. At various points during the electrolysis process the currentfrom the power supply is terminated stopping the electrolysis processes.The electrolyte in the cell is mixed or circulated to insure uniformityand both the liquid phase and solid phase are sampled. The solid phaseis filtered to remove liquid and the sample is analyzed for compositionusing typical analytical methods such as atomic absorption, AA, orInductively coupled plasma Atomic Emission Spectroscopy, ICP-AES. Fromthe composition analysis of the solid and liquid phases and knowledge ofthe initial electrolyte composition a solubility diagram demarking thesolid and solution phase regions can be produced. Likewise the celloperating line can be determined from the overall mass balance.

The initial composition of the electrolyte can be changed and theprocess repeated to find a composition where solids do not appear,relative to the solubility profile curve of the metal oxide. This is themaximum. Referring again to FIG. 3, operating lines are shown for a cellhaving an initial concentration of 45% KOH and for a cell having aninitial concentration of 38% KOH. As predicted in the experimentaldesign of Table 2, precipitate was not observed during operation of thecell.

Step 403 of the method is choosing a concentration of M₃OH that is inthe range of at and within 5% less than the maximum concentration ofM₃OH to be the initial concentration of M₃OH. This range typicallyallows for the most efficient operation of the electrochemical cell,i.e., the highest yield and purity of hydride gas such as, for example,arsine, is generated. Preferably, the mole % of arsenic produced by themethod of the present invention is at least 90%, more preferably atleast 92%, even more preferably at least 94%, and most preferably atleast 95%. Preferably, the % purity of the hydride gas generated overthe life of the electrochemical cell according to the present inventionis at least 99%, more preferably at least 99.9%, and most preferably atleast 99.999%.

EXAMPLES

The following examples are provided for the purpose of furtherillustrating the present invention but are by no means intended to limitthe same.

Experimental Conditions for all Examples Listed in Table 3

Each cell was constructed and operated under similar conditions asillustrated below.

Referring to FIG. 1 again, the anode 3 consisted of four molybdenumplates (99%) with dimensions ⅛″×1.5″×7.5″. They were placed in avertical-lengthwise, symmetric square-pattern (2″×2″) around the centralcathode rod and connected via a common electrical conducting stainlesssteel frame. They had a nominal mass of 1000 grams. The conducting framewas located above the electrolyte solution.

The cathode 2 consisted of a single arsenic rod, 1.5″ diameter×6″height, was mounted vertically and placed in the center of the squarepattern formed by the molybdenum plates. A single ⅛″ stainless steel rodwas centered within the arsenic rod and extended beyond the top of thearsenic rod to facilitate electrical contact. The cathode had a nominalmass of 1000 grams.

The anodes 3 and cathode 2 were placed in a cylindrical stainless vessel1 and isolated from the electrically conducting surfaces usingpolyethylene and Teflon liners and spacers.

The cell was filled with an aqueous solution of potassium hydroxide. Thecell was then sealed and electrical contact was made throughelectrically isolated connections. A single outlet 4 for the gas of thecell was directed to a gas analyzer. A constant current of 2.5 amps wassupplied to the electrochemical cell from an external constant currentpower supply. Gas analysis with a Balzers Pfeiffer QMA-430 QuadrapoleMass Spectrometer confirmed that the principle gases formed in the cellwere arsine and hydrogen. The gas formed was also analyzed forcomposition, using a Lorex Gas Analyzer, Model number PZN-SS-003-4 Themass of arsine produced was confirmed gravimetrically by weighing theelectrochemical cell.

Six experiments were performed with various KOH solutions described inTable 3. In each experiment both molybdenum and arsenic were in excessand the limiting chemical reagent was potassium hydroxide, 1 gram ofpotassium KOH has the potential to generate 1.39 grams of arsine, AsH₃.

Examples 1 and 2 High Concentration of Hydroxide

An electrochemical cell was constructed and operated according to theconditions described above. Examples 1 and 2 illustrated in Table 3 wereoperated with a high concentration of potassium hydroxide (45%). Underthese conditions the yield of arsine was 65.7% and 50.0% based on thelimiting reagent potassium hydroxide. Inspection of the cell revealedthe formation of a large amount of crystals, which substantially filledthe space between the anode and cathode.

In Example 1, the purity of the arsenic rod was 99% and the arsinepurity was limited to 85% with 15% hydrogen. Increasing the purity ofthe arsenic to 99.999% increased the gas purity 90% in Example 2.

Examples 3, 4, 5 and 6 Optimal Concentration of Hydroxide

An electrochemical cell was constructed and operated according to theconditions in Example 1. Examples 3, 4 and 5 were operated at highconcentrations of potassium hydroxide (39%) which, based oncalculations, were just below the saturation curve. Example 6 wasoperated at high concentrations of potassium hydroxide (38%) which,based on calculations, was just below the saturation curve. Under theseconditions the yield of arsine ranged between 71.4% and 77.8% based onthe limiting reagent potassium hydroxide compared to Examples 1 and 2.Inspection of the cell revealed that there were no crystals formed.

For the 99% pure arsenic in Example 3 the arsine purity was 92% and whenthe 99.999% purity arsenic was used in Examples 4, 5 and 6 the arsinepurity increased to 94% to 95%. FIG. 4 illustrates the improvedgeneration of arsine gas for Example 5 up to the point of failure at 704grams of arsine produced.

Comparison of Examples 1-6

When the hydroxide solution is the limiting reagent in theelectrochemical production of a hydride, one would predict based onstoichiometry that increasing the concentration of the limiting reagentshould increase the yield of arsine. This, however, is not the case.When the system was operated at a hydroxide concentration of 45%,formation of solid precipitate occurred and the arsine yields werelimited to from 50.3% to 65.7%. When the hydroxide concentration waskept high, but just below the saturation curve (38% to 39%), solidprecipitate did not form and the arsine yields increased to from 71.4%to 77.8%. Operating at high hydroxide concentration, where solids didnot form, increased the yield of arsine compared to conditions whichformed solids (see Table 3).

For similar arsenic purity the absence of solids allowed the process togenerate higher purity arsine gas. When 99% arsenic was used operationwith solids generated 85% pure arsine which increased to 90% arsine whenthe operation did not generate solids. Likewise for 99.999% arsenic, thepurity increased from 92% to 95% when the operation shifted from theproduction of solids to conditions where solids were not produced.

Tables 4 (detailed) and 5 (key results from Table 4) illustrate twoimportant results for a generator which has a limited electrolyte volumeof 1 liter. First, the gas quality is improved with lower KOH. Next, anoptimum in the yield of Arsine occurs at 39% KOH. At low KOHconcentration the amount of arsine is limited to the low levels of KOHno matter how efficient the process is. At high levels of KOH the yieldin grams is low because the solids formed in the process interfere withthe process.

TABLE 3 Arsenic Purity, Concentration Mass of % over the Mole % Arsine**Yield in Theoretical yield Molar Solid crystals of KOH KOH, useful ingas (remainder = grams of based on Yield of covering Experiment wt %grams generation life hydrogen) arsine. KOH Arsine the cathode 1 45% 641   99% 85% 585 890 65.7% Yes 2 45% 638 99.999% 92% 445 886 50.3% Yes 339% 681    99% 90% 675 946 71.4% No 4 39% 688 99.999% 95% 736 955 77.2%No 5 39% 704 99.999% 94% 720 978 74.6% No 6 38% 660 99.999% 95% 714 91777.8% No **Note that the yield of arsine was measured at the point wherethe concentration of arsine dropped sharply to less than 80% purity withincreasing production.

TABLE 4 Experiments with limited electrolyte volume Mole % TheoreticalMolar Yield of Solid Concentration Mass of Electrolyte Arsine in gasyield Arsine crystals of Density, KOH, Volume, Arsenic (remainder =based on with KOH as covering the Yield in grams Experiment KOH wt %kg/m3 grams liters Purity % hydrogen) KOH limiting reagent cathode ofarsine. 7 45 1457 655.7 1.00 99.999 92.0 886.0 50.3% Yes 445.7 8 39 1390542.1 1.00 99.999 94.5 732.6 75.9% No 556.0  9* 10 1092 109.2 1.0099.999 94.5 147.6 100.0% No 147.6 *The molar yield of arsine is assumedin this example to be 100%.

TABLE 5 Experiments with 1 liter of KOH electrolyte. Mole % Arsine ingas Concentration (remainder = Yield in Experiment of oKOH wt %hydrogen) grams of arsine. 7 45% 92.0% 445.7 8 39% 94.5% 556.0  9* 10%94.5% 147.6

Examples 7-14 Effect of Excess of Solids from the Anode Reaction Example7

An undivided temperature controlled electrochemical cell made of Teflon®will be constructed with an internal volume of 10 cc of liquid. Amolybdenum anode (99% purity) with a surface area of 2.8 cm² will bepositioned 3.8 cm from an antimony cathode (>99% purity) with a surfacearea of 2.8 cm². An aqueous electrolyte containing 35% potassiumhydroxide will be charged to the cell. An electrical potential of 5.0 Vwill be applied to the cell while the aqueous electrolyte temperaturewill be maintained at 0° C. using an external cooling bath. Stibinealong with hydrogen will be evolved from the cell. A current rangingfrom 0.6 to 0.8 amps and a stibine production rate of 0.7 mg/min will beobtained.

Example 8

An undivided temperature controlled electrochemical cell made of Teflon®will be constructed with an internal volume of 10 cc of liquid. Amolybdenum anode (99% purity) with a surface area of 2.8 cm² will bepositioned 3.8 cm from an antimony cathode (>99% purity) with a surfacearea of 2.8 cm². An aqueous electrolyte containing 35% potassiumhydroxide saturated with potassium molybdate, K₂MoO₄, and containingfree potassium molybdate solids will be charged to the cell. Anelectrical potential of 5.0 V will be applied to the cell while theaqueous electrolyte temperature will be maintained at 0° C. using anexternal cooling bath. Stibine along with hydrogen will be evolved fromthe cell. A current ranging from 0.05 to 0.10 amps and a stibineproduction rate of 0.08 mg/min will be obtained.

Example 9

An undivided temperature controlled electrochemical cell made of Teflon®will be constructed with an internal volume of 10 cc of liquid. Atungsten anode (99% purity) with a surface area of 2.8 cm² will bepositioned 3.8 cm from an arsenic cathode (>99% purity) with a surfacearea of 2.8 cm². An aqueous electrolyte containing 35% sodium hydroxidewill be charged to the cell. An electrical potential of 5.0 V will beapplied to the cell while the aqueous electrolyte temperature will bemaintained at 21° C. using an external cooling bath. Arsine along withhydrogen will be evolved from the cell. A current ranging from 1.0 to1.2 amps and an arsine production rate of 16.0 mg/min will be obtained.

Example 10

An undivided temperature controlled electrochemical cell made of Teflon®will be constructed with an internal volume of 10 cc of liquid. Atungsten anode (99% purity) with a surface area of 2.8 cm² will bepositioned 3.8 cm from an arsenic cathode (>99% purity) with a surfacearea of 2.8 cm². An aqueous electrolyte containing 35% sodium hydroxidesaturated with potassium tungstate, NaWO₄, and containing free potassiumtungstate solids will be charged to the cell. An electrical potential of5.0 V will be applied to the cell while the aqueous electrolytetemperature will be maintained at 21° C. using an external cooling bath.Arsine along with hydrogen will be evolved from the cell. A currentranging from 0.15 to 0.2 amps and an arsine production rate of 2.5mg/min will be obtained.

Example 11

An undivided temperature controlled electrochemical cell made of Teflon®will be constructed with an internal volume of 10 cc of liquid. Atungsten anode (99% purity) with a surface area of 2.8 cm² will bepositioned 3.8 cm from a black phosphorous cathode (>99% purity) with asurface area of 2.8 cm². An aqueous electrolyte containing 35% potassiumhydroxide will be charged to the cell. An electrical potential of 5.0 Vwill be applied to the cell while the aqueous electrolyte temperaturewill be maintained at 21° C. using an external cooling bath. Phosphinealong with hydrogen will be evolved from the cell. A current rangingfrom 1.0 to 1.2 amps and a phosphine production rate of 2.0 mg/min willbe obtained.

Example 12

An undivided temperature controlled electrochemical cell made of Teflon®will be constructed with an internal volume of 10 cc of liquid. Atungsten anode (99% purity) with a surface area of 2.8 cm² will bepositioned 3.8 cm from a black phosphorous cathode (>99% purity) with asurface area of 2.8 cm². An aqueous electrolyte containing 35% potassiumhydroxide saturated with potassium tungstate, K₂WO₄, and containing freepotassium tungstate solids will be charged to the cell. An electricalpotential of 5.0 V will be applied to the cell while the aqueouselectrolyte temperature will be maintained at 21° C. using an externalcooling bath. Phosphine along with hydrogen will be evolved from thecell. A current ranging from 0.15 to 0.2 amps and a phosphine productionrate of 0.3 mg/min will be obtained.

Example 13

An undivided temperature controlled electrochemical cell made of Teflon®will be constructed with an internal volume of 10 cc of liquid. Amolybdenum anode (99% purity) with a surface area of 2.8 cm² will bepositioned 3.8 cm from a germanium, Ge, cathode (>99% purity) with asurface area of 2.8 cm². An aqueous electrolyte containing 35% potassiumhydroxide will be charged to the cell. An electrical potential of 5.0 Vwill be applied to the cell while the aqueous electrolyte temperaturewill be maintained at 21° C. using an external cooling bath. Germane,GeH₄, along with hydrogen will be evolved from the cell. A currentranging from 1.0 to 1.2 amps and a germane production rate of 0.5 mg/minwill be obtained.

Example 14

An undivided temperature controlled electrochemical cell made of Teflon®will be constructed with an internal volume of 10 cc of liquid. Amolybdenum anode (99% purity) with a surface area of 2.8 cm² will bepositioned 3.8 cm from a germanium cathode (>99% purity) with a surfacearea of 2.8 cm². An aqueous electrolyte containing 35% potassiumhydroxide saturated with potassium molybdate, K₂MoO₄, and containingfree potassium molybdate solids will be charged to the cell. Anelectrical potential of 5.0 V will be applied to the cell while theaqueous electrolyte temperature will be maintained at 21° C. using anexternal cooling bath. Germane, GeH₄, along with hydrogen will beevolved from the cell. A current ranging from 0.15 to 0.2 amps and agermane production rate of 0.08 mg/min will be obtained.

Examples 7-14 illustrate that a cell operated with an electrolyte withexcess of solids from the anode reaction leads to a lower productionrates of the hydride gas compared to operation with an electrolyte whichwill be not saturated with solids.

The foregoing examples and description of the preferred embodimentsshould be taken as illustrating, rather than as limiting the presentinvention as defined by the claims. As will be readily appreciated,numerous variations and combinations of the features set forth above canbe utilized without departing from the present invention as set forth inthe claims. Such variations are not regarded as a departure from thespirit and scope of the invention, and all such variations are intendedto be included within the scope of the following claims.

1. A method for generating a hydride gas of metal M₁ in anelectrochemical cell comprising a cathode comprising metal M₁; asacrificial anode comprising metal M₂; an initial concentration ofaqueous electrolyte solution comprising a metal hydroxide, M₃OH; whereinthe sacrificial metal anode electrochemically oxidizes in the presenceof the aqueous electrolyte solution to form a metal salt, and thehydride gas of metal M₁ is formed by reducing the metal M₁ of thecathode, the method comprising the steps of: determining solubilityprofile curves of the metal salt as the M₃OH is consumed and the metaloxide is formed by the oxidation reaction at various concentrations ofM₃OH; determining a maximum concentration of M₃OH using the solubilityprofile curves; said determined maximum concentration of M₃OH does notyield a concentration of metal salt that precipitates out of theelectrolyte solution; and choosing a concentration of M₃OH that is inthe range of at and within 5% less than the said determined maximumconcentration of M₃OH to be an initial concentration of M₃OH.
 2. Themethod for generating a hydride gas of metal M₁ in an electrochemicalcell of claim 1 wherein M1 is selected from the group consisting of Sb,As, Se , P, Ge, Zn, Pb, Cd and alloys thereof.
 3. The method forgenerating a hydride gas of metal M₁ in an electrochemical cell of claim1 wherein said sacrificial anode is selected from the group consistingof hydrogen oxidation anode, redox anode and soluble, oxidizible ionicspecies with an oxidation potential less than 0.4 volts versus an Hg/HgOreference electrode.
 4. The method for generating a hydride gas of metalM₁ in an electrochemical cell of claim 1 wherein said sacrificial anodeis a hydrogen oxidation anode and M2 is selected from the groupconsisting of molybdenum, tungsten, vanadium, cadmium, lead, nickelhydroxide, chromium, antimony, arsenic and alloys thereof.
 5. The methodfor generating a hydride gas of metal M₁ in an electrochemical cell ofclaim 1 wherein said sacrificial anode is a redox anode, and is selectedfrom the group consisting of MnO₂/MnO₃, Fe(OH)₂/Fe₃O₄, Ag₂O/Ag₂O₂, andCo(OH)₃/Co(OH)₂.
 6. The method for generating a hydride gas of metal M₁in an electrochemical cell of claim 1 wherein M₃ in said metalhydroxide, M₃OH, is selected from the group consisting of alkali andalkaline earth metals.
 7. The method for generating a hydride gas ofmetal M₁ in an electrochemical cell of claim 6 wherein M₃OH is selectedfrom the group consisting of NaOH, KOH, LiON, CsOH, NH₄OH andcombinations thereof.